red996

Great thread. I was wondering where you were going to get the internal engine parts you need to rebuild this engine. I thought Porsche was'nt selling any 996/997 internal parts.

Imo000

Pelican is selling everything I need and the prices are better than ebay. Looks like $750 plus the fluids will be enough to get the engine done. Clutch will be a seperate cost. If a Boxter S clutch is the same, I have a lead on a very low mileage one. Ebay has a couple set of good used ones too.

Imo000

The passanger side exhaust valves were leaking because of carbon build up in the seats. Took two out and re lapped them. The intake valves are good. Took one out to see, the rest of them will not be touched. Only have to lap the exhaust ones.

Cosmo Kramer

The poor boosted 928 has been relegated to a parts shelf for the 911!

Great progress Imre! Are you going to touch the IMS bearings?

Imo000

Yes the 928 is the parts shelf at the moment. I would like to replace the IMS but so far the only option I can see is the LN unit. I might bite the bullet and get that.

petee_c

If you get the LN unit, I might rent/borrow the IMS removal tool from you at some point seeing as you're fairly close to me.

I've got a Boxster S with 98K km on it, and the IMS is on my list of things to do someday....

Oh... u might not need the tool.... you've got the engine apart....

P

Imo000

I will need the bearing puller for sure. The engine is not taken apart enough, only the heads are off. My father has a machine shop so I will just make one instead of buying/renting one.

Imo000

Decided to pull and relap all the valves, including the intakes. The method will be to take all 4 valves out, relap them, then clean out all the ports and then reinstall the valves. This will be done one cylinder at a time and it will take a crapload of time. . First pic is the somewhat cleared out work bench. Second are the Intake ports from the passanger side head, note the extreme carbon build up. Third is one of the intake ports cleaned. Forth s both cleaned and the last one of all the carbon that came out of only these two ports. The exhaust ports are very clean so it will be an easier job.

996_North

Man you are hooked up...Great thread. Probably best quote ever.

Is all that carbon build-up normal for an engine with that amount of mileage ? What causes it ?

Imo000

I think the air oil seperator failed a long time ago and was never replaced. I will pull the lines off the seperator soon to see how heavy the oil build up is in them. Should be an interesting site. In some of the early pictures you can see the seperator was leaking coolant for a very long time too.

The silver lining in all this is, the dealer send me an email that the PO dropped off two more keys and he is mailing them. I wasn't expecting this.

aviography

Good news with the keys, those two keys would have cost you upwards of $4~500 at a Porsche dealership.

How did you clean the built-up carbon? Some sort of plastic scraper?

Imo000

It was a small (twice the size of a tooth brush) wire brush that I bought as a 3 pack at Princess Auto a few years ago to fix my DD. BUT most of it was scraped off with a simple flathead screwdriver. The buildup was very soft but at least 3mm thick.

I'm happy about the extra keys as my 928 only has one.

red996

When I didn't see anything on Pelican for 997 engine parts I thought I was right. Turns out Porsche shows 997 engine parts on
http://www.porsche.com/uk/accessorie...artscatalogue/

Question is why wouldn't someone just rebuild a 997 engine in the garage instead of buying a replacement engine? If you can rebuild a 996 engine why not a 997 engine?

jumper5836

because skill in not learned in the stealerships. Much easier to replace the whole component and charge for the same hours.

Imo000

Quality of work too. An engine plant has the proper tools/jigs to put one together faster with very little chance for a screw up. Besides this, its a lot cheaper for Porsche too pay for a simple replace than to take a chance at an amature rebuild. Because lets face it, rebuilding an engine at a dealership is amature work when compared to the factory.